An automatic curing method and system for concrete

Abstract

This invention discloses an automatic concrete curing method and system, relating to the field of concrete curing technology. The automatic concrete curing method includes the following steps: determining the curing type of the concrete based on the initial ambient temperature; arranging the corresponding curing system in the climbing formwork according to the curing type and the state of the climbing formwork; and using the curing system to cure the concrete according to the ambient temperature and humidity during the curing process. This invention can solve the problems of inadequate curing, difficulty in adjusting curing humidity and strength according to changes in temperature and humidity, and low safety for workers during water spraying.

Description

Technical Field

[0001] This invention relates to the field of concrete curing technology, specifically to an automatic concrete curing method and system. Background Technology

[0002] With the rapid development of infrastructure construction and the continuous improvement of engineering quality standards, concrete structures play an irreplaceable role in infrastructure construction. Therefore, concrete quality control is an important factor in ensuring engineering quality, and concrete curing is a crucial link in quality assurance.

[0003] In bridge construction, main towers are typically constructed using reinforced concrete. Due to geological and climatic conditions, some bridge projects are located in areas with dry climates, insufficient rainfall, large diurnal temperature variations, and high wind speeds. The combined effect of these factors exacerbates concrete water loss, significantly increasing its susceptibility to cracking. Currently, the industry standard practice is manual curing. However, traditional manual watering has several problems: First, humidity control is difficult, especially for concrete exposed to the elements where moisture evaporates quickly, easily leading to interruptions in curing. Second, achieving full coverage is challenging, particularly for vertical structures like towers, piers, and piles, resulting in inadequate localized curing. Third, adjusting curing intensity based on temperature is inconvenient. Fourth, manual watering requires significant manpower, including operators and managers, and the process must be standardized, cautious, and continuous. Inadequate management can easily lead to incomplete or interrupted curing, affecting concrete strength.

[0004] Furthermore, the current automatic concrete curing devices based on the climbing formwork system have limitations in that they cannot change the curing humidity and curing intensity of concrete according to changes in temperature and humidity. In projects with long construction periods, they cannot change the curing methods according to winter and non-winter conditions. The devices are too simplistic. Although they solve the problem of manual watering, the precision and scope of curing are insufficient. Summary of the Invention

[0005] In view of the deficiencies in the existing technology, the first aspect of the present invention provides an automatic curing method for concrete, which can solve the problems of inadequate curing, difficulty in adjusting curing humidity and strength according to changes in temperature and humidity, and low safety of workers when watering construction.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] An automatic curing method for concrete, comprising the following steps:

[0008] Determine the type of concrete curing based on the initial ambient temperature;

[0009] Based on the type of concrete curing and the condition of the climbing formwork, the corresponding curing system is arranged in the climbing formwork.

[0010] The concrete is cured using a curing system based on the ambient temperature and humidity during the curing process.

[0011] In some embodiments, determining the curing type of concrete based on the initial ambient temperature includes:

[0012] When the initial ambient temperature is higher than the first temperature, the concrete should be kept moist and cured.

[0013] When the initial ambient temperature is lower than the first temperature, the concrete should be kept warm and cured.

[0014] In some embodiments, the step of arranging the corresponding curing system in the climbing formwork according to the curing type of concrete and the state of the climbing formwork includes:

[0015] When concrete is kept moist and the formwork is in the process of being removed from the formwork and then lifted:

[0016] The main unit of the curing system and multiple slave units of the curing system are arranged on the climbing formwork, and the ultrasonic atomizer is arranged on the top surface of the climbing formwork near the currently poured concrete segment.

[0017] Water supply pipes connecting the ultrasonic atomizer are arranged along the climbing mold;

[0018] Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding ultrasonic atomizer.

[0019] In some embodiments, the step of arranging the corresponding curing system in the climbing formwork according to the curing type of concrete and the state of the climbing formwork includes:

[0020] When the concrete is kept moist and curing is carried out, and the climbing formwork has finished climbing:

[0021] The main unit of the curing system and multiple slave units are arranged on the climbing formwork, and the ultrasonic atomizer is arranged on the climbing formwork to cover the currently poured concrete segment.

[0022] Water supply pipes connecting the ultrasonic atomizer are arranged along the climbing mold;

[0023] Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding ultrasonic atomizer.

[0024] In some embodiments, the step of using a curing system to cure concrete based on the ambient temperature and humidity during the curing process includes:

[0025] The highest ambient humidity is used as the first priority. When the temperature and humidity sensor detects that the ambient humidity during the maintenance process is higher than the highest humidity, the ultrasonic atomizer is controlled to stop spraying.

[0026] The highest ambient temperature is used as the second priority. When the temperature and humidity sensor detects that the ambient temperature during the maintenance process is higher than the highest temperature and the duration exceeds 15 minutes, the ultrasonic atomizer is controlled to start spraying.

[0027] The lowest ambient temperature is used as the third priority. When the temperature and humidity sensor detects that the ambient temperature during the maintenance process is lower than the lowest temperature, the ultrasonic atomizer is controlled to stop spraying.

[0028] In some embodiments, the step of arranging the corresponding curing system in the climbing formwork according to the curing type of concrete and the state of the climbing formwork includes:

[0029] When the concrete is insulated and cured, and the formwork is in the demolding and climbing stage:

[0030] Insulation material is installed on the climbing formwork frame and climbing formwork panels;

[0031] The main maintenance unit, multiple slave maintenance units, and multiple steam generators of the maintenance system are arranged on the climbing formwork.

[0032] Water supply pipes connecting to the steam generator are arranged along the climbing formwork, as well as steam pipes branching off from the steam generator and extending upwards to the top surface of the demolding area;

[0033] Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding steam generator.

[0034] In some embodiments, the step of arranging the corresponding curing system in the climbing formwork according to the curing type of concrete and the state of the climbing formwork includes:

[0035] When the concrete is insulated and cured, and the climbing formwork has finished climbing:

[0036] Insulation material is installed on the climbing formwork frame and climbing formwork panels;

[0037] The main maintenance unit, multiple slave maintenance units, and multiple steam generators of the maintenance system are arranged on the climbing formwork.

[0038] Water supply pipes connecting to the steam generator are arranged along the climbing formwork, as well as steam pipes branching off from the steam generator and extending along both ends of the currently poured concrete.

[0039] Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding steam generator.

[0040] In some embodiments, the step of using a curing system to cure concrete based on the ambient temperature and humidity during the curing process includes:

[0041] Set the target temperature for maintenance;

[0042] When the temperature and humidity sensor detects that the ambient temperature during the curing process exceeds the target curing temperature, it controls the steam generator to stop supplying steam.

[0043] When the temperature and humidity sensor detects that the ambient temperature during the maintenance process is lower than the target temperature, it controls the steam generator to start supplying steam.

[0044] In some embodiments, the first temperature is 5°C.

[0045] The second aspect of this invention provides an automatic concrete curing system that can solve the problems of inadequate curing, difficulty in adjusting curing humidity and strength according to changes in temperature and humidity, and low safety for workers during water spraying construction.

[0046] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0047] An automatic concrete curing system, comprising:

[0048] climbing model;

[0049] A maintenance host, multiple maintenance slave units, multiple temperature and humidity sensors, and a maintenance terminal are installed on the climbing formwork. The maintenance terminal includes devices that can select at least two different maintenance types based on the initial ambient temperature.

[0050] The maintenance host and maintenance slave can control the start and stop of the maintenance terminal based on temperature and humidity sensors, and the maintenance host, multiple maintenance slaves and maintenance terminals can adjust their positions and arrangements in the climbing formwork according to the state of the climbing formwork.

[0051] Compared with the prior art, the advantages of the present invention are as follows:

[0052] The automatic concrete curing method of this invention employs the following approach: determining the concrete curing type based on the initial ambient temperature; arranging the corresponding curing system within the climbing formwork according to the curing type and the state of the formwork; and utilizing the curing system to cure the concrete based on the ambient temperature and humidity during the curing process. Specifically, during the construction of vertical structures such as bridge towers, the curing system is integrated with the climbing formwork. The curing system ascends with the formwork, and intelligent spray pipes, temperature and humidity sensors, ultrasonic atomizers, and steam generators are installed within the formwork. After demolding, the intelligent curing system sprays, atomizes, and steam-insulates the poured reinforced concrete structure, achieving automatic curing of the reinforced concrete. This allows for adjustment of the curing intensity, temperature, and humidity based on changes in temperature and humidity. Furthermore, this intelligent curing system is suitable for projects with long construction periods, as the intelligent curing equipment can be adjusted on the climbing formwork according to climate changes, achieving both summer moisture retention and winter insulation with a single installation. Attached Figure Description

[0053] Figure 1 This is a flowchart of the automatic concrete curing method in an embodiment of the present invention;

[0054] Figure 2 This is an elevation layout diagram of the spray curing scaffold during the demolding-climbing period in an embodiment of the present invention;

[0055] Figure 3 This is a cross-sectional view of the spray curing pipeline during the demolding-climbing period in an embodiment of the present invention;

[0056] Figure 4 This is an elevation view of the climbing frame after the spray curing climbing frame has been raised in an embodiment of the present invention;

[0057] Figure 5 This is a cross-sectional view of platform L-1 after the spray curing climbing frame has climbed up in an embodiment of the present invention;

[0058] Figure 6 This is a cross-sectional view of the L+0 platform after the spray curing climbing frame has climbed in an embodiment of the present invention;

[0059] Figure 7 This is an elevation layout diagram of the steam curing climbing frame during the demolding-climbing period in an embodiment of the present invention.

[0060] Figure 8 This is a diagram showing the elevation layout of the top surface steam curing during the 12-hour demolding-climbing interval in an embodiment of the present invention.

[0061] Figure 9 This is a diagram showing the steam curing elevation layout after the steam curing scaffold has ascended in an embodiment of the present invention.

[0062] Figure 10 This is a cross-sectional view of the steam curing pipeline after the steam curing climbing frame has been raised in an embodiment of the present invention;

[0063] Figure 11 yes Figure 10 A cross-sectional view along the AA direction. Detailed Implementation

[0064] The technical solutions (including preferred technical solutions) of the present invention will be further described in detail below with reference to the accompanying drawings and by way of listing some optional embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0065] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0066] Furthermore, in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, without necessarily requiring or implying any such actual relationship or order between these entities or operations. Moreover, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0067] To address the following problems existing in concrete curing technology:

[0068] (1) When using manual watering to cure reinforced concrete structures, it is difficult to control the curing humidity. The moisture in concrete evaporates quickly in open-air operations, which can easily lead to interruption of moisturizing curing.

[0069] (2) During bridge construction, manual watering is difficult to fully cover the reinforced concrete structure, and local curing is easily inadequate.

[0070] (3) Manual watering maintenance makes it difficult to adjust the maintenance intensity according to the temperature.

[0071] (4) Manual watering maintenance requires a lot of manpower, the operation during the maintenance process requires certain requirements, and training operation and management personnel requires a certain amount of time and economic costs. Furthermore, the use of manual watering for the maintenance of reinforced concrete structures in some vertical structures has a significant impact on the safety of operators and makes it difficult to guarantee their safety.

[0072] (5) The use of manual watering for vertical structures in bridge engineering makes it difficult to make effective use of water resources and will result in the waste of water resources.

[0073] (6) Existing automatic concrete curing devices based on climbing formwork systems are not intelligent or systematic enough. They are difficult to adjust the curing intensity and humidity precisely according to changes in temperature and humidity. The curing methods are too simple and cannot be adjusted according to climate changes.

[0074] This invention proposes an automatic concrete curing method. During the pouring of reinforced concrete for the tower body in bridge engineering, an intelligent curing system is deployed in the climbing formwork. The entire system ascends with the climbing formwork. After each layer of concrete is poured, the intelligent curing system sprays, atomizes, and steams the bridge tower body during the demolding gap and the climbing stage, achieving intelligent and automatic curing of the reinforced concrete of the bridge tower body. This solves the problems of inadequate curing, difficulty in adjusting curing humidity and strength according to changes in temperature and humidity, and low safety of workers when watering during traditional reinforced concrete curing methods.

[0075] Specifically, see Figure 1 As shown in the figure, an embodiment of the present invention discloses an automatic curing method for concrete, which includes the following steps:

[0076] S1. Determine the curing type of the concrete based on the initial ambient temperature.

[0077] Specifically, in this embodiment, the choice between moisturizing maintenance and heat preservation maintenance is mainly based on the initial ambient temperature.

[0078] Specifically, when the initial ambient temperature is higher than the first temperature, the concrete is subjected to moisture curing; when the initial ambient temperature is lower than the first temperature, the concrete is subjected to heat preservation curing.

[0079] In this embodiment, the first temperature is 5°C. When the initial ambient temperature is higher than 5°C, a non-winter maintenance plan, i.e., moisturizing maintenance, should be adopted; while when the initial ambient temperature is lower than 5°C, a winter maintenance plan, i.e., heat preservation maintenance, should be adopted. It is understood that the value of the first temperature can be reasonably set according to needs, and this embodiment does not impose any restrictions.

[0080] S2. Based on the type of concrete curing and the condition of the climbing formwork, arrange the corresponding curing system in the climbing formwork.

[0081] S3. Based on the ambient temperature and humidity during the curing process, use a curing system to cure the concrete.

[0082] Since the curing methods are divided into moisturizing curing and heat preservation curing, and the state of the climbing formwork is different, the arrangement of the curing system will be different, and the way to use the curing system to cure the concrete will also be different. The following will explain them according to the curing methods and the state of the climbing formwork.

[0083] For moisturizing and maintenance, the following methods are adopted depending on the condition of the mold:

[0084] When concrete is kept moist and the formwork is in the process of being removed from the formwork and then lifted:

[0085] The main unit of the curing system and multiple slave units of the curing system are arranged on the climbing formwork, and the ultrasonic atomizer is arranged on the top surface of the climbing formwork near the currently poured concrete segment.

[0086] Water supply pipes connecting the ultrasonic atomizer are arranged along the climbing mold;

[0087] Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding ultrasonic atomizer.

[0088] When the concrete is kept moist and curing is carried out, and the climbing formwork has finished climbing:

[0089] The main unit of the curing system and multiple slave units are arranged on the climbing formwork, and the ultrasonic atomizer is arranged on the climbing formwork to cover the currently poured concrete segment.

[0090] Water supply pipes connecting the ultrasonic atomizer are arranged along the climbing mold;

[0091] Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding ultrasonic atomizer.

[0092] Correspondingly, when taking moisturizing care measures, step S3 includes:

[0093] The highest ambient humidity is used as the first priority. When the temperature and humidity sensor detects that the ambient humidity during the maintenance process is higher than the highest humidity, the ultrasonic atomizer is controlled to stop spraying.

[0094] The highest ambient temperature is used as the second priority. When the temperature and humidity sensor detects that the ambient temperature during the maintenance process is higher than the highest temperature and the duration exceeds 15 minutes, the ultrasonic atomizer is controlled to start spraying.

[0095] The lowest ambient temperature is used as the third priority. When the temperature and humidity sensor detects that the ambient temperature during the maintenance process is lower than the lowest temperature, the ultrasonic atomizer is controlled to stop spraying.

[0096] For thermal insulation and curing, the following methods are adopted depending on the condition of the climbing formwork:

[0097] When the concrete is insulated and cured, and the formwork is in the demolding and climbing stage:

[0098] Insulation material is installed on the climbing formwork frame and climbing formwork panels;

[0099] The main maintenance unit, multiple slave maintenance units, and multiple steam generators of the maintenance system are arranged on the climbing formwork.

[0100] Water supply pipes connecting to the steam generator are arranged along the climbing formwork, as well as steam pipes branching off from the steam generator and extending upwards to the top surface of the demolding area;

[0101] Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding steam generator.

[0102] When the concrete is insulated and cured, and the climbing formwork has finished climbing:

[0103] Insulation material is installed on the climbing formwork frame and climbing formwork panels;

[0104] The main maintenance unit, multiple slave maintenance units, and multiple steam generators of the maintenance system are arranged on the climbing formwork.

[0105] Water supply pipes connecting to the steam generator are arranged along the climbing formwork, as well as steam pipes branching off from the steam generator and extending along both ends of the currently poured concrete.

[0106] Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding steam generator.

[0107] Correspondingly, when adopting heat preservation and curing methods, step S3 includes:

[0108] Set the target temperature for maintenance;

[0109] When the temperature and humidity sensor detects that the ambient temperature during the curing process exceeds the target curing temperature, it controls the steam generator to stop supplying steam.

[0110] When the temperature and humidity sensor detects that the ambient temperature during the maintenance process is lower than the target temperature, it controls the steam generator to start supplying steam.

[0111] The steps in the embodiments of the present invention will be further described below with reference to the accompanying drawings:

[0112] 1. Non-winter maintenance plan (when the temperature is >5℃)

[0113] Overall Design: Tower Body: Flame-retardant tarpaulin + intelligent spray maintenance

[0114] Tower top: Plastic film + geotextile for moisture retention and maintenance

[0115] 1.1 Water supply system:

[0116] ① The water used for maintenance is drawn from the river (mountain spring) and purified to filter algae, impurities, and neutralize corrosiveness.

[0117] ② The purification tank is equipped with a float valve to achieve automatic water intake.

[0118] ③ The purification tank is placed inside the foundation. The full load weight of a single water tank is 6t, and the concrete bearing surface pressure is 1.5MPa.

[0119] ④ The maintenance water pipes (or cleaning pipes) are made of seamless steel pipes with a diameter of 60mm or larger, a wall thickness of 4mm, and a pressure resistance of 6.4MPa. The steel pipes are connected by flanges and extended section by section along the inner wall of the tower column as the pouring progresses. The pressure pump is a multi-stage vertical energy-saving pump with a head of not less than 350m and a flow rate of not less than 16m³ / h. The water supply pipes are pre-embedded in the concrete, increasing in size as the climbing stage progresses, with a diameter of 60mm and a pressure resistance of 2.4MPa. The maintenance pipes are arranged around the tower column and fixed to the vertical rods of the climbing frame, 600-700mm away from the concrete surface.

[0120] Curing System: Each tower uses 2 sets of intelligent cement concrete curing hosts, and one curing host is set up for each tower segment. Each host has 8 channels and is equipped with 8 temperature and humidity sensors. Each channel controls one ultrasonic atomizer.

[0121] 1.2 First Stage: 12 hours from template detachment to climb, see [link / reference] Figure 2 and Figure 3 As shown.

[0122] (1) Host Layout

[0123] ①The host is placed on any one of the four faces of the L-1 platform.

[0124] ② Connect the control cable between the main unit and the ultrasonic atomizer.

[0125] (2) Moisturizing wrapping coverage

[0126] If the formwork is separated from the concrete surface by 20cm, it is only necessary to cover the top perimeter with geomembrane.

[0127] (3) Water supply pipe installation

[0128] The water supply pipe has been extended to the top surface of the L+2 platform, and is on the same plane as the ultrasonic atomizer. Simply connect the water supply pipe.

[0129] (4) Arrangement of ultrasonic atomizer

[0130] Four ultrasonic atomizers are installed on the top surface of the newly poured segment (one on each surface).

[0131] 1.3 Second Stage: Post-climb spray protection, see [link / reference] Figures 4 to 6 As shown.

[0132] (1) Host Layout

[0133] ①The host is placed on any one of the four faces of the L-1 platform.

[0134] ② Connect the control cable between the main unit and the ultrasonic atomizer.

[0135] (2) Moisturizing wrapping coverage

[0136] From L-1 to L+0, wrap one layer of flame-retardant tarpaulin; from L-1 to the bottom of this section (6m), wrap one layer of flame-retardant tarpaulin (using L-2 as the operating platform). After the tarpaulin passes through the diagonal pole, cut it open and then glue it with Velcro.

[0137] (3) Water supply pipe installation

[0138] Water supply pipes from the top surface of this section are led to the L+0 and L-1 platforms, respectively, and connected to four ultrasonic humidifiers.

[0139] (4) Arrangement of ultrasonic atomizer

[0140] ① Four ultrasonic atomizers are arranged on the L+0 platform and numbered 1-4;

[0141] ② Four ultrasonic atomizers are arranged on the L-1 platform, numbered 5-8.

[0142] The curing height is 6m, and the volume of the flame-retardant tarpaulin covering is approximately 400-500m³. 3 Each ultrasonic atomizer corresponds to a filling volume of 50-60m³. 3 .

[0143] 1.4 Maintenance process and data upload:

[0144] (1) The system comes with its own process program

[0145] ① The system prioritizes the highest humidity level and will not start when the ambient humidity is above 95%.

[0146] ②The highest temperature is used as the second priority control. If the ambient temperature is higher than the set value, such as 40℃, for more than 15 minutes, the system will automatically start to adjust the temperature and humidity.

[0147] ③The heat of hydration is controlled with the lowest temperature as the third priority, and the system will not start if the ambient temperature is below 5℃;

[0148] ④ Finally, use clock control: gradually reduce the spraying frequency as the age increases.

[0149] (2) Data Upload ① Each ultrasonic atomizer corresponds to one set of temperature and humidity sensors. Temperature ±0.5°C, humidity ±5.0%RH. ② Temperature is monitored in real time, which can be viewed through a mobile APP and uploaded to the corresponding big data platform via serial port connection.

[0150] 1.5 Moisture retention and maintenance plan for the top of the tower and the top surface of each segment

[0151] Plastic film + geotextile for moisture retention

[0152] ① Measure and record the surface temperature of the concrete;

[0153] ② A layer of plastic film should be laid on the surface of newly poured concrete;

[0154] ③ Cover the plastic film with geotextile.

[0155] 2. Winter maintenance plan (when the temperature is <5℃)

[0156] 2.1 Windproof and heat-insulating climbing formwork

[0157] ① The climbing formwork frame (-1 and -2 layers) is wrapped with flame-retardant tarpaulin. The tarpaulin is installed on the outside of the protective net and is fixed to the protective net with wire.

[0158] ② Install temperature and humidity sensors inside the climbing frame to monitor the temperature inside the climbing frame.

[0159] 2.2 Insulation of Climbing Formwork Panel

[0160] ① The climbing formwork panel is filled with flame-retardant rubber sponge between the wooden I-beams to achieve the heat preservation effect;

[0161] ②When the template closing and tie rods damage the rubber sponge, it needs to be replaced or filled in time to ensure that the template has a good heat preservation effect.

[0162] 2.3 Extend the demolding time

[0163] ①The winter curing period with molds should not be less than 7 days;

[0164] ② When removing the formwork, it is necessary to ensure that the temperature difference between the formwork and the external environment is less than 20℃, and that the strength of the specimen cured under the same conditions is greater than 40% of the design strength before the formwork can be removed.

[0165] ③ The formwork should be removed during the day when the temperature is higher.

[0166] 2.4 Steam conveying and insulation

[0167] ① After the template is removed, apply a curing solution promptly for curing;

[0168] ② Steam curing is carried out in the curing shed, and the temperature and humidity are recorded regularly. The temperature in the curing shed is not lower than 15℃.

[0169] ③ After the concrete is poured, promptly cover the exposed concrete surface with plastic film, black cotton quilt, and tarpaulin.

[0170] 2.4.1 Maintenance System Control Principle

[0171] The curing system consists of four main parts: a curing master unit, multiple curing slave units, wireless temperature and humidity testing terminals, and curing terminals (insulation tarpaulin and steam pipelines). Each curing master unit or slave unit corresponds to a set of wireless temperature and humidity testing terminals. The central controller of the master unit automatically performs calculations based on the temperature and humidity data monitored by each wireless temperature and humidity terminal to determine whether the corresponding curing master (slave) unit should start (or stop) and deliver steam through the steam curing pipeline network to the insulation tarpaulin. The entire curing process automatically executes the steam curing process according to the programmed settings, ensuring the temperature and humidity requirements at each stage of steam curing. The wireless temperature and humidity testing terminals feed back the temperature and humidity test data to the central processor in the control center every 15 seconds for real-time processing.

[0172] 2.4.2 Maintenance System Equipment Configuration and Performance

[0173] Two maintenance systems are used for each main tower. Each maintenance system includes one main unit and three cluster units (expandable). Each main unit and cluster unit corresponds to one set of temperature and humidity sensors. The temperature monitoring accuracy is ±0.5°C, and the humidity monitoring accuracy is ±5.0%RH.

[0174] 2.5 First Stage: Template detachment to climb (12 hours), see [link / reference] Figure 7 and Figure 8 As shown.

[0175] ① Equipment layout

[0176] One main unit and three cluster units are arranged on the L-1 platform of the climbing formwork for each tower segment;

[0177] ② Equipment water supply

[0178] Water is supplied by a water supply pipe embedded in the tower column, and a water delivery pipe is led out from the L+2 platform to the L-1 platform.

[0179] ③ Temperature and humidity data collection

[0180] One set of temperature and humidity sensors is installed on each side.

[0181] ④ Steam pipe layout

[0182] Steam pipe: Single-layer steel wire hose with a diameter of 25mm, temperature resistance up to 230℃, pressure resistance up to 1.6MPa, with 1.5mm holes every 1.5m-2.0m, arranged around the top surface of the demolding area down to about 50cm.

[0183] ⑤ Steam transport

[0184] A steam pipe branches off from the machine at 2 / 4 of its length, extending from platform L-1 to platform L+2, and then connects to steam pipes 5-1 and 5-2 respectively. Each pipe is 30m long (at this time, the previous segment is about 10 days old).

[0185] ⑥ Airtight insulation

[0186] The perimeter is insulated with templates (with external insulation sponge), and the corners and top are wrapped with insulation sponge or cotton wool.

[0187] 2.6 Second Stage: Steam Curing After Climbing, see [link / reference] Figures 9 to 11 As shown.

[0188] ① Equipment layout

[0189] One main unit and three cluster units are arranged on the L-1 platform of the climbing formwork for each tower segment; the positions remain unchanged from the previous stage.

[0190] ② Equipment water supply

[0191] Water is supplied by a water supply pipe embedded in the tower column, and a water delivery pipe is led out from the L+0 platform to the L-1 platform.

[0192] ③ Temperature and humidity data collection

[0193] One set of temperature and humidity sensors is installed on each side.

[0194] ④ Steam pipe layout

[0195] Steam pipe: Single-layer steel wire hose with a diameter of 25mm, temperature resistant up to 230℃, pressure resistant up to 1.6MPa, with 1.5mm holes every 1.5m-2.0m. Two loops are installed at 0.5m and 3.5m down from the top surface of the section, respectively.

[0196] ⑤ Steam transport

[0197] Units 1-4 correspond to steam pipes 1-4 respectively, with steam pipes 1 and 3 responsible for supplying steam to the upper layer and steam pipes 2 and 4 responsible for supplying steam to the lower layer.

[0198] ⑥ Insulation and sealing

[0199] From L-1 to L+0, wrap the section with one layer of flame-retardant tarpaulin; from L-1 to the bottom of this section (6m), wrap the section with one layer of flame-retardant tarpaulin (using L-2 as the operating platform). After the tarpaulin passes through the diagonal pole, cut it open and glue it with Velcro. Wrap other corner positions with insulating sponge or cotton wadding for insulation.

[0200] 2.7 Steam Curing Process

[0201] The maintenance process temperature is 15±1°C. The gas supply will automatically stop if the temperature exceeds 16°C, and will automatically start if the temperature is below 14°C.

[0202] Based on the above description, the automatic concrete curing method of the present invention has the following characteristics:

[0203] As the construction season changes, the intelligent curing system and other equipment on the climbing scaffold will be replaced to adapt to different climates and temperatures, ensuring the quality of concrete curing.

[0204] During non-winter construction, the climbing scaffold is equipped with a curing host, ultrasonic atomizer, temperature and humidity sensor, water supply rubber hose, and moisture-retaining tarpaulin, etc., which are attached to the climbing scaffold and rise together to ensure the moisture retention effect of the reinforced concrete of the tower.

[0205] During winter construction, the climbing scaffold is equipped with a steam generator, a moisture-retaining tarpaulin, an infinite temperature and humidity sensor, steam pipes, and water supply rubber hoses. The entire system is attached to the climbing scaffold and rises with it. During winter maintenance, the system can be installed in one go, ensuring the insulation effect of the reinforced concrete tower.

[0206] The curing system consists of four main parts: a curing master unit, multiple curing slave units, wireless temperature and humidity testing terminals, and curing terminals (insulation tarpaulin and steam pipelines). Each curing master unit or slave unit corresponds to a set of wireless temperature and humidity testing terminals. The central controller of the master unit automatically performs calculations based on the temperature and humidity data monitored by each wireless temperature and humidity terminal to determine whether the corresponding curing master (slave) unit should start (or stop) and deliver steam through the steam curing pipeline network to the insulation tarpaulin. The entire curing process automatically executes the steam curing process according to the programmed settings, ensuring the temperature and humidity requirements at each stage of steam curing. The wireless temperature and humidity testing terminals feed back the temperature and humidity test data to the central processor in the control center every 15 seconds for real-time processing.

[0207] The curing system's built-in process program prioritizes the highest humidity level; the system will not start when the ambient humidity exceeds 95%. It prioritizes the highest temperature level; if the ambient temperature exceeds the set value (e.g., 40℃) for more than 15 minutes, the system will automatically start to adjust the temperature and humidity. Hydration heat is prioritized at the lowest temperature; the system will not start if the ambient temperature is below 5℃. Finally, it uses clock control: the spraying frequency gradually decreases as the age of the plant increases.

[0208] In addition, each ultrasonic atomizer corresponds to a set of temperature and humidity sensors. Real-time temperature monitoring can be viewed through a mobile APP and uploaded to the corresponding big data platform via serial port connection.

[0209] In summary, the automatic concrete curing method of this invention employs the following approach: determining the concrete curing type based on the initial ambient temperature; arranging the corresponding curing system within the climbing formwork based on the concrete curing type and the state of the formwork; and utilizing the curing system to cure the concrete according to the ambient temperature and humidity during the curing process. Specifically, during the construction of vertical structures such as bridge towers, the curing system is integrated with the climbing formwork. The curing system ascends with the climbing formwork, and intelligent spray pipes, temperature and humidity sensors, ultrasonic atomizers, and steam generators are installed within the formwork. After demolding, the intelligent curing system sprays, atomizes, and steam-insulates the poured reinforced concrete structure, achieving automatic curing of the reinforced concrete. This allows for adjustments to the curing intensity, temperature, and humidity of the reinforced concrete based on changes in temperature and humidity. Furthermore, this intelligent curing system is suitable for projects with long construction periods, as the intelligent curing equipment can be adjusted on the climbing formwork according to climate changes, achieving both summer moisture retention and winter insulation with a single installation.

[0210] Meanwhile, this invention also discloses an automatic concrete curing system, which includes a climbing formwork; a curing master unit, multiple curing slave units, multiple temperature and humidity sensors, and a curing terminal mounted on the climbing formwork. The curing terminal includes equipment capable of selecting at least two different curing types based on the initial ambient temperature. Specifically, it mainly includes equipment related to moisture-retaining curing and heat-insulating curing.

[0211] The maintenance host and maintenance slave can control the start and stop of the maintenance terminal based on temperature and humidity sensors, and the maintenance host, multiple maintenance slaves and maintenance terminals can adjust their positions and arrangements in the climbing formwork according to the state of the climbing formwork.

[0212] The foregoing is merely a list of specific embodiments of the present application, intended to enable those skilled in the art to understand or implement the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments shown herein, but is intended to conform to the broadest scope consistent with the principles and novel features of the present application.

Claims

1. A method for automatic curing of concrete, characterized in that, The method includes the following steps: Determine the type of concrete curing based on the initial ambient temperature; Based on the type of concrete curing and the condition of the climbing formwork, the corresponding curing system is arranged in the climbing formwork. The concrete is cured using a curing system based on the ambient temperature and humidity during the curing process. The determination of the concrete curing type based on the initial ambient temperature includes: When the initial ambient temperature is higher than the first temperature, the concrete should be kept moist and cured. When the initial ambient temperature is lower than the first temperature, the concrete should be insulated and cured. The method of arranging the corresponding curing system in the climbing formwork according to the curing type of concrete and the state of the climbing formwork includes: When concrete is kept moist and the formwork is in the process of being removed from the formwork and then lifted: The main unit of the curing system and multiple slave units of the curing system are arranged on the climbing formwork, and the ultrasonic atomizer is arranged on the top surface of the climbing formwork near the currently poured concrete segment. Water supply pipes connecting the ultrasonic atomizer are arranged along the climbing mold; Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit and its corresponding ultrasonic atomizer. When the concrete is kept moist and curing is carried out, and the climbing formwork has finished climbing: The main unit of the curing system and multiple slave units are arranged on the climbing formwork, and the ultrasonic atomizer is arranged on the climbing formwork to cover the currently poured concrete segment. Water supply pipes connecting the ultrasonic atomizer are arranged along the climbing mold; Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding ultrasonic atomizer.

2. The automatic curing method for concrete according to claim 1, characterized in that, The curing system is used to cure concrete based on the ambient temperature and humidity during the curing process, including: The highest ambient humidity is used as the first priority. When the temperature and humidity sensor detects that the ambient humidity during the maintenance process is higher than the highest humidity, the ultrasonic atomizer is controlled to stop spraying. The highest ambient temperature is used as the second priority. When the temperature and humidity sensor detects that the ambient temperature during the maintenance process is higher than the highest temperature and the duration exceeds 15 minutes, the ultrasonic atomizer is controlled to start spraying. The lowest ambient temperature is used as the third priority. When the temperature and humidity sensor detects that the ambient temperature during the maintenance process is lower than the lowest temperature, the ultrasonic atomizer is controlled to stop spraying.

3. The automatic curing method for concrete according to claim 1, characterized in that, The method of arranging the corresponding curing system in the climbing formwork according to the curing type of concrete and the state of the climbing formwork includes: When the concrete is insulated and cured, and the formwork is in the demolding and climbing stage: Insulation material is installed on the climbing formwork frame and climbing formwork panels; The main maintenance unit, multiple slave maintenance units, and multiple steam generators of the maintenance system are arranged on the climbing formwork. Water supply pipes connecting to the steam generator are arranged along the climbing formwork, as well as steam pipes branching off from the steam generator and extending upwards to the top surface of the demolding area; Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding steam generator.

4. The automatic curing method for concrete according to claim 1, characterized in that, The method of arranging the corresponding curing system in the climbing formwork according to the curing type of concrete and the state of the climbing formwork includes: When the concrete is insulated and cured, and the climbing formwork has finished climbing: Insulation material is installed on the climbing formwork frame and climbing formwork panels; The main maintenance unit, multiple slave maintenance units, and multiple steam generators of the maintenance system are arranged on the climbing formwork. Water supply pipes connecting to the steam generator are arranged along the climbing formwork, as well as steam pipes branching off from the steam generator and extending along both ends of the currently poured concrete. Temperature and humidity sensors are installed between the main maintenance unit, each slave maintenance unit, and its corresponding steam generator.

5. A method for automatic curing of concrete according to claim 3 or 4, characterized in that, The curing system is used to cure concrete based on the ambient temperature and humidity during the curing process, including: Set the target temperature for maintenance; When the temperature and humidity sensor detects that the ambient temperature during the curing process exceeds the target curing temperature, it controls the steam generator to stop supplying steam. When the temperature and humidity sensor detects that the ambient temperature during the maintenance process is lower than the target temperature, it controls the steam generator to start supplying steam.

6. The automatic curing method for concrete according to claim 1, characterized in that: The first temperature is 5°C.

7. An automatic concrete curing system for implementing the automatic concrete curing method as described in claim 1, characterized in that, include: climbing model; A maintenance host, multiple maintenance slave units, multiple temperature and humidity sensors, and a maintenance terminal are installed on the climbing formwork. The maintenance terminal includes devices that can select at least two different maintenance types based on the initial ambient temperature. The maintenance host and maintenance slave can control the start and stop of the maintenance terminal based on temperature and humidity sensors, and the maintenance host, multiple maintenance slaves and maintenance terminals can adjust their positions and arrangements in the climbing formwork according to the state of the climbing formwork.

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